Direct wire terminal assembly

Abstract

A terminal assembly includes a cable including a conductor having at least one wire. The conductor has an outer surface. The terminal assembly includes a terminal having a main body extending between a front portion and a rear portion of the terminal. The terminal includes a wire support that supports the at least one wire of the conductor at a mating interface. The at least one wire is welded to the wire support to secure the at least one wire to the main body of the terminal. The outer surface of the conductor is exposed at the mating interface for direct mating to a mating component.

Description

Technical Field

[0001] This article mainly deals with electrical connectors. Background Technology

[0002] Electrical connectors are used to electrically connect components. For example, electrical connectors may include receptacle connectors, plug connectors, headstock connectors, etc. Electrical connectors typically include a housing that retains terminals or contacts. Contacts mate with each other at mating interfaces to electrically connect first and second electrical connectors. Cable connectors include a cable terminated to contacts. For example, the cable may be crimped to the contacts at a termination end. The contacts include a mating end opposite the termination end, configured to mate with a mating contact of a mating electrical connector. To enhance conductivity, contacts are typically made of a highly conductive material, such as copper. Contacts are typically stamped and formed to include specific types of mating interfaces, such as pins, receptacles, spring beams, or other mating interfaces that mate with the mating contact.

[0003] Electrical connectors are not without their drawbacks. For example, copper contacts tend to be more expensive than other types of contacts, increasing the overall cost of the connector. Additionally, the mating ends of the contacts add to the cost, requiring complex stamping and forming processes and additional material to form the mating interface. Furthermore, conventional connectors include multiple interfaces or transitions along the transmission line, such as at each cable-to-contact interface and at each contact-to-contact interface. Performance degradation can occur at each interface or transition.

[0004] There is still a need for a cost-effective and reliable electrical connector. Summary of the Invention

[0005] In one embodiment, a terminal assembly is provided, comprising a cable including a conductor having at least one wire. The conductor has an outer surface. The terminal assembly includes a terminal having a body extending between a front portion and a rear portion of the terminal. The terminal includes a wire support that supports at least one wire of the conductor at a mating interface. The at least one wire is soldered to the wire support to secure the at least one wire to the body of the terminal. The outer surface of the conductor is exposed at the mating interface for direct mating to a mating member.

[0006] In another embodiment, a terminal assembly is provided, comprising a cable including a conductor having at least one wire. The conductor includes a front portion, a rear portion, and a mating portion between the front and rear portions. The terminal assembly includes a terminal having a body extending between the front and rear portions of the terminal. The terminal includes a front solder pad soldered to the front portion of the conductor and a rear solder pad soldered to the rear portion of the conductor. The terminal includes a wire support that supports the mating portion of the conductor at the mating interface. The mating portion of the conductor is exposed at the mating interface for direct mating with a mating component.

[0007] In another embodiment, an electrical connector is provided, comprising a housing having a mating end configured to mate with a mating member and a cable end. The housing includes a contact channel passing through it. The electrical connector includes a terminal assembly coupled to the housing. The terminal assembly includes a cable and a terminal coupled to the cable. The cable includes a conductor having at least one wire. The terminal has a body extending between a front portion and a rear portion of the terminal. The terminal includes a wire support that supports at least one wire of the conductor at the mating interface. The at least one wire is soldered to the wire support to secure the at least one wire to the body of the terminal. The conductor is exposed at the mating interface for direct mating with a mating member. Attached Figure Description

[0008] Figure 1 An electrical connector system according to an exemplary embodiment is shown.

[0009] Figure 2 This is a top view of an electrical connector according to an exemplary embodiment.

[0010] Figure 3 This is a perspective view of an electrical connector according to an exemplary embodiment.

[0011] Figure 4 This is a bottom perspective view of an electrical connector according to an exemplary embodiment.

[0012] Figure 5 This is an exploded bottom perspective view of an electrical connector according to an exemplary embodiment.

[0013] Figure 6 The terminals of a terminal assembly according to an exemplary embodiment are shown.

[0014] Figure 7 This is a front perspective view of a terminal assembly according to an exemplary embodiment, showing a terminal connected to the end of a cable.

[0015] Figure 8 This is a rear perspective view of a terminal assembly according to an exemplary embodiment, showing a terminal connected to the end of a cable.

[0016] Figure 9 This is a side view of a terminal assembly according to an exemplary embodiment, showing a terminal connected to the end of a cable.

[0017] Figure 10 Multiple terminals on a carrier strip according to an exemplary embodiment are shown.

[0018] Figure 11 This is a front perspective view of a terminal assembly according to an exemplary embodiment, showing a terminal connected to the end of a cable.

[0019] Figure 12 This is a cross-sectional view of the first electrical connector according to an exemplary embodiment.

[0020] Figure 13 An electrical connector system according to an exemplary embodiment is shown, which illustrates first and second electrical connectors in a mating state.

[0021] Figure 14 This is a cross-sectional view of an electrical connector system according to an exemplary embodiment, showing the first and second electrical connectors in a mating state.

[0022] Figure 15 This is an enlarged cross-sectional view of an electrical connector system according to an exemplary embodiment, showing a first electrical connector and a second electrical connector in a mating state.

[0023] Figure 16 An electrical connector system according to an exemplary embodiment is shown, which illustrates a first electrical connector prepared to mate with mating parts.

[0024] Figure 17 An electrical connector system according to an exemplary embodiment is shown, which illustrates a first electrical connector that mates with mating parts.

[0025] Figure 18 This is a cross-sectional view of an electrical connector system according to an exemplary embodiment, showing a first electrical connector mating with mating parts.

[0026] Figure 19 This is an enlarged cross-sectional view of an electrical connector system according to an exemplary embodiment, showing a first electrical connector mating with mating parts.

[0027] Figure 20 An electrical connector system according to an exemplary embodiment is shown, which illustrates a first electrical connector that mates with mating parts. Detailed Implementation

[0028] Figure 1An electrical connector system 100 according to an exemplary embodiment is shown. The electrical connector system 100 includes a first electrical connector 200 electrically connected to a first component 102 and a second electrical connector 300 electrically connected to a second component 104. The electrical connectors 200 and 300 mate at separable mating interfaces. The electrical connectors 200 and 300 transmit data and / or power between the first component 102 and the second component 104.

[0029] In an exemplary embodiment, the first electrical connector 200 is a cable connector having one or more cables 202 extending from it. In an alternative embodiment, the first electrical connector 200 may be a board connector terminating on a circuit board (not shown). In an alternative embodiment, instead of a second electrical connector 300, the first electrical connector 200 may directly mate with the circuit board. For example, the first electrical connector 200 may be a snap-edge connector configured to receive an edge of the circuit board.

[0030] In an exemplary embodiment, the second electrical connector 300 is a cable connector having one or more cables 302 extending from it. In an alternative embodiment, the second electrical connector 300 may be a board connector terminating on a circuit board. In an alternative embodiment, instead of the second electrical connector 300, it may directly mate with the circuit board. For example, the second electrical connector 300 may be a snap-edge connector configured to receive an edge of the circuit board.

[0031] The second electrical connector 300 includes a housing 320 that holds one or more terminal assemblies 350. Each terminal assembly 350 includes a terminal 360 terminating at the end of a corresponding cable 302. The cable 302 can be soldered to the corresponding terminal 360. For example, the cable 302 can be spot-welded at multiple locations along the terminal 360, such as at or near the front of the terminal 360, and / or at or near the rear of the terminal 360, and / or at or near the center portion of the terminal 360. The cable 302 can be ultrasonically soldered to the terminal 360. Optionally, the conductor of the cable 302 can be a multi-strand cable, wherein the individual strands of the cable 302 can be soldered to each other at one or more locations along the length of the strands. The terminal 360 provides mechanical support for the conductor of the cable 302 at a mating interface for mating with the first electrical connector 200. For example, the terminal 360 supports and positions the cable 302 at the mating interface. The conductor can be soldered to the terminal 360 at and / or in front of and / or behind the mating interface. Terminal 360 can provide a normal force against cable 302 to press cable 302 outward at the mating interface for mating with the first electrical connector 200. In an exemplary embodiment, the conductor of cable 302 is configured to directly mate with a corresponding cable 202 of the first electrical connector 200. Terminal 360 may additionally or alternatively be crimped to the end of cable 302.

[0032] In an exemplary embodiment, the first and second electrical connectors 200 and 300 are identical. For example, the first and second electrical connectors 200 and 300 may be mirror-matched halves of the electrical connector system 100. The second electrical connector 300 may be rotated 180° relative to the first electrical connector 200 to mate with it. Optionally, the first electrical connector 200 and the second electrical connector 300 may be hermaphroditic. The first electrical connector 200 and / or the second electrical connector 300 may include retaining elements, such as latches, to ensure mating between the first and second electrical connectors 200 and 300.

[0033] Figure 2 This is a top view of an electrical connector 200 according to an exemplary embodiment. Figure 3 This is a perspective view of an electrical connector 200 according to an exemplary embodiment. Figure 4 This is a bottom perspective view of the electrical connector 200 according to an exemplary embodiment. Figure 5 This is an exploded bottom perspective view of an electrical connector 200 according to an exemplary embodiment.

[0034] The electrical connector 200 includes a housing 220 that holds one or more terminal assemblies 250. In the illustrated embodiment, the electrical connector 200 includes five terminal assemblies 250 arranged in a single row. In alternative embodiments, the electrical connector 200 may include more or fewer terminal assemblies 250. In alternative embodiments, the terminal assemblies 250 may be arranged in multiple rows, such as an upper row and a lower row. Each terminal assembly 250 includes a terminal 260 and a corresponding cable 202. The terminal 260 terminates at an end of the cable 202 and provides support for the end of the cable 202 for mating with a mating component (e.g., a second electrical connector 300).

[0035] In an exemplary embodiment, terminal assembly 250 is a direct wire terminal assembly, wherein the wires of cable 202 are configured to terminate directly to a mating component. For example, the wires define a mating interface configured to directly engage with a mating component (e.g., directly with the wires of cable 302 of the corresponding terminal assembly of the second electrical connector 300). In an exemplary embodiment, electrical connector system 100 provides a direct wire-to-wire, separable mating interface between the first and second electrical connectors 200, 300. In an alternative embodiment, electrical connector system 100 provides a direct wire-to-board, separable mating interface between the wires of cable 202 and the contact pads of a circuit board mating with the first electrical connector 200.

[0036] The housing 220 is made of a dielectric material, such as plastic. Optionally, the housing 220 may be a molded part. The housing 220 extends between a mating end 222 and a cable end 224. The cable 202 extends from the cable end 224. In the illustrated embodiment, the cable end 224 is opposite to the mating end 222 (e.g., at the rear and front, respectively). In an alternative embodiment, the housing 220 may be a right-angled housing having the cable end 224 perpendicular to the mating end 222 (e.g., at the bottom and front, respectively).

[0037] In an exemplary embodiment, housing 220 is rectangular. Housing 220 includes a front portion 230, a rear portion 232, a top portion 234, a bottom portion 236, and a side portion 238 between the top portion 234 and the bottom portion 236 and / or between the front portion 230 and the rear portion 232. In alternative embodiments, housing 220 may have other shapes. In an exemplary embodiment, housing 220 has a low profile. For example, housing 220 has a short height between the top portion 234 and the bottom portion 236. In an exemplary embodiment, mating end 222 is disposed at the front portion 230, and cable end 224 is disposed at the rear portion 232. In alternative embodiments, other orientations are possible.

[0038] Housing 220 includes one or more terminal channels 240 for receiving corresponding terminal assemblies 250. In the illustrated embodiment, housing 220 includes five terminal channels 240. However, in alternative embodiments, housing 220 may include more or fewer terminal channels 240. In the illustrated embodiment, the terminal channels 240 extend between a front portion 230 and a rear portion 232. For example, the terminal channels 240 may open at the front portion 230 and / or at the rear portion 232 to receive terminal assemblies 250. In the illustrated embodiment, cable 202 extends from the terminal channel 240 at the rear portion 232.

[0039] In an exemplary embodiment, housing 220 includes a mating groove 242 at a front portion 230. In the illustrated embodiment, the mating groove 242 extends between sides 238. An upper wall 241 may be located between a top 234 and the mating groove 242, and / or a lower wall 243 may be located between a bottom 236 and the mating groove 242. The upper wall 241 may accommodate a terminal assembly 250. In an exemplary embodiment, the upper wall 241 is configured to be inserted into a mating groove of a second electrical connector 300 during mating. The mating groove 242 is configured to receive mating components (e.g., the second electrical connector 300 or a circuit board). The terminal assembly 250 is exposed in the mating groove 242 for mating with mating components. For example, a terminal channel 240 may open into the mating groove 242 to expose the mating end of the terminal assembly 250.

[0040] In an alternative embodiment, instead of an elongated mating groove, housing 220 may include a separate mating cavity for receiving a corresponding mating terminal assembly 250 of the mating component. For example, mating groove 242 may be separated by partition walls to form a separate mating cavity.

[0041] In an exemplary embodiment, housing 220 includes guiding features to guide mating with the second electrical connector 300. In the illustrated embodiment, the guiding features include a guide rail 244 on the upper wall 241 and a guide groove 245 on the lower wall 243. The guide rail 244 is configured to insert into the guide groove in the housing of the second electrical connector 300. The guide groove 245 is configured to receive the guide rail of the housing of the second electrical connector 300. Other types of guiding features may be used in alternative embodiments. In the illustrated embodiment, the guiding feature is centered on housing 220. Other positions are also possible in alternative embodiments. The guiding feature may define a keying feature for keying mating with the second electrical connector 300.

[0042] In an exemplary embodiment, housing 220 includes a retaining feature for securely engaging with the second electrical connector 300. In the illustrated embodiment, the retaining feature includes a latch 246 on side 238 and / or a snap 247 on side 238. The latch 246 is deflectable. The latch 246 is configured to engage with a corresponding snap on the housing of the second electrical connector 300. The snap 247 is configured to engage with a latch on the second electrical connector 300. In alternative embodiments, other types of retaining features may be used. In alternative embodiments, the retaining feature may be located at other locations, such as at top 234 and / or bottom 236.

[0043] Figure 6 Terminal 260 of terminal assembly 250 according to an exemplary embodiment is shown. Figure 7 This is a front perspective view of the terminal assembly 250 according to an exemplary embodiment, showing the terminal 260 connected to the end of the cable 202. Figure 8 This is a rear perspective view of the terminal assembly 250 according to an exemplary embodiment, showing the terminal 260 connected to the end of the cable 202. Figure 9 This is a side view of the terminal assembly 250 according to an exemplary embodiment, showing a terminal 260 connected to the end of the cable 202.

[0044] Cable 202 includes a conductor 204 and an insulator 206 surrounding the conductor 204. The insulator 206 may define an outer sheath of the cable 202. In an alternative embodiment, the insulator 206 may be an inner layer of the cable 202 having a cable shield and an outer sheath surrounding the insulator 206. In an exemplary embodiment, the conductor 204 is a multi-strand conductor having a plurality of strands or wires 208 forming the conductor 204. The wires 208 may be copper or copper alloy wires, or other highly conductive metal wires, such as aluminum or aluminum alloys, or pre-tinned wires. The wires 208 are arranged in bundles. A bundle of wires 208 may have one or more rows and / or one or more columns of wires 208. The wires 208 may internest with each other within the bundle, for example, by placing wires from different rows in grooves or spaces between adjacent wires 208 formed in the bundle. The wires 208 may be twisted along the length of the cable 202. Cable 202 may have any number of strands 208, the number of which may depend on the strand specifications. For example, cable 202 may be a twenty (20) gauge cable with ten (10) strands 208. In various other embodiments, cable 202 may be a twenty-two (22) gauge cable with seven (7) strands 208. Larger or smaller gauge cables may be used in alternative embodiments. In various other embodiments, cable 202 may include a solid conductor 204 having a single strand 208.

[0045] In an exemplary embodiment, cable 202 is fabricated by removing a portion of insulator 206 to form an exposed portion 210 of conductor 204. The exposed portion 210 of conductor 204 is located at the end of cable 202. The exposed portion 210 of conductor 204 is configured for direct electrical connection to a mating component (e.g., a second electrical connector 300). The exposed portion 210 of conductor 204 includes a front portion 212, a rear portion 216, and a mating portion 214 between the front portion 212 and the rear portion 216. The front portion 212 and the rear portion 216 are connected to a terminal 260. For example, the front portion 212 and the rear portion 216 may be soldered to the terminal 260. The front portion 212 and the rear portion 216 may be ultrasonically welded or laser welded to the terminal 260. In other embodiments, the front portion 212 and the rear portion 216 may be soldered to the terminal 260. The mating portion 214 may be connected to the terminal 260. For example, mating portion 214 may be soldered to terminal 260. Mating portion 214 may be ultrasonically welded or laser welded to terminal 260. In other embodiments, mating portion 214 may be soldered to terminal 260. Mating portion 214 is configured for direct electrical connection to mating components. For example, mating portion 214 defines a mating interface 218 of conductor 204 (e.g., at the outer surface 219 of conductor 204). Mating interface 218 is defined by the outer surface 209 of one or more wires 208. For example, the top edge of the outermost wire 208 may define mating interface 218. In an exemplary embodiment, multiple wires 208 are disposed at and define mating interface 218.

[0046] In an exemplary embodiment, terminal 260 is a stamped component. Terminal 260 may be stamped from a single sheet of metal and formed into a predetermined shape to receive the end of cable 202. Optionally, a plurality of terminals 260 may be stamped from a carrier strip and subsequently individualized from the carrier strip (e.g., cut). Terminal 260 is configured to terminate at the end of cable 202, for example, by welding (e.g., ultrasonic welding or laser welding) to the end of cable 202. Terminal 260 may additionally or alternatively be crimped to the end of cable 202.

[0047] Terminal 260 includes a body 262 extending between a front portion 264 and a rear portion 266. Terminal 260 includes other features stamped together with and extending from the body 262, such as features for soldering to cable 202, positioning terminal 260 within housing 220, or other features. In an exemplary embodiment, body 262 includes a front base 265 and a rear base 267 spaced apart from each other, for example, adjacent to front portion 264 and rear portion 266, respectively. Front base 265 and rear base 267 may be coplanar with each other. However, in an alternative embodiment, front base 265 and rear base 267 may be offset (e.g., vertically offset). Front base 265 supports a front portion 212 of conductor 204. Front base 265 may form a solder pad. Front portion 212 may be soldered to front base 265. Rear base 267 supports a rear portion 216 of conductor 204. Rear base 267 may form a solder pad. The rear portion 216 can be welded to the rear base 267.

[0048] In an exemplary embodiment, terminal 260 serves as mechanical support for cable 202, for example, positioning the conductor 204 of cable 202 for direct engagement with mating components. For instance, terminal 260 supports and positions cable 202 at a mating interface. Terminal 260 can provide a normal force against cable 202 to press cable 202 outward at the mating interface for engagement with the second electrical connector 300. Terminal 260 itself is not used for electrical engagement with mating components. Instead, the conductor 204 of cable 202 is configured to directly engage with mating components. Thus, terminal 260 can be made of less expensive materials compared to conventional terminals with mating contacts integrated into it.

[0049] In an exemplary embodiment, terminal 260 is made of stainless steel. Stainless steel is less expensive than copper or aluminum, which are commonly used for electrical terminals. In an exemplary embodiment, terminal 260 has a density of less than 3.0 × 10⁻⁶ at 20°C. 7 The conductivity is S / m, while the conductor 204 defining the electrical interface that mates with the mating parts has a conductivity greater than 3.0 × 10⁻⁶ at 20°C. 7 Conductivity in S / m, for example, greater than 5.0 × 10⁻⁶ at 20℃. 7 S / m (for example, a copper conductor at 20°C can have approximately 5.96 × 10⁻⁶ S / m). 7 (Conductivity in IACS). In an exemplary embodiment, terminal 260 may have a conductivity of less than 30 IACS (International Standard for Annealed Copper). For example, terminal 260 may be a stainless steel terminal with a conductivity of less than 3.0 IACS. Conversely, conductor 204 defining the electrical mating interface that mates with mating components may include copper wire with a conductivity of approximately 100 IACS, or aluminum or an aluminum alloy with a conductivity between approximately 40 and 60 IACS.

[0050] Terminal 260 includes one or more connecting elements 270 configured to be mechanically connected to cable 202. In an exemplary embodiment, connecting element 270 includes a front solder pad 272 and a rear solder pad 274. The front solder pad 272 is located near the front portion 264 of terminal 260. For example, the front solder pad 272 is disposed at or extends from the front base 265. The front solder pad 272 is configured to receive and solder to the front portion 212 of conductor 204. For example, the front solder pad 272 may include a flat pad and / or sides forming a channel to support and retain a bundle of wires 208, thereby supporting the wires 208 at the front solder pad 272. The rear solder pad 274 is located behind the front solder pad 272, for example, near the rear portion 266. For example, the rear solder pad 274 is disposed at or extends from the rear base 267. The rear solder pad 274 is configured to receive and solder to the rear portion 216 of conductor 204. For example, the rear pad 274 may include a flat pad and / or sides forming a channel to support and retain a bundle of wires 208, thereby supporting the wires 208 at the rear pad 274. In an exemplary embodiment, the connecting element 270 includes a central pad 273 between the front pad 272 and the rear pad 274. The central pad 273 is configured to receive and solder to the mating portion 214 of the conductor 204. For example, the central pad 273 may include a flat pad and / or sides forming a channel to support and retain a bundle of wires 208, thereby supporting the wires 208 at the central pad 273.

[0051] In an exemplary embodiment, the connecting element 270 may include a crimp arm 276 configured to crimp onto the cable 202. For example, the crimp arm 276 may form an insulating crimp portion configured to crimp onto the insulator 206. The insulating crimp portion is located behind the rear solder pad 274. The insulating crimp portion may be located at or near the rear portion 266 of the terminal 260. The insulating crimp portion may include opposing crimp arms that crimp around the insulator 206 to surround and / or compress the insulator 206. The crimp arm 276 may be disposed at a front base 265 and / or a rear base 267 to crimp onto the front portion 212 and / or the rear portion 216 of the conductor.

[0052] Terminal 260 includes a wire support 280 that supports the wires 208 of conductor 204, for example at a front base 265 and / or a rear base 267, and / or at a mating interface 218. In an exemplary embodiment, the wire support 280 extends between the front base 265 and the rear base 267 of body 262. The wire support 280 may be soldered to the wires 208, for example, at the front base 265 and / or the rear base 267 and / or the central solder pad 273. The wire support 280 supports conductor 204 for direct mating with the second electrical connector 300 (e.g., mating to a conductor of a corresponding terminal assembly of the second electrical connector 300 or mating to a contact pad of a circuit board). The outer surface of conductor 204 (e.g., the outer surface of the outermost wire 208) is exposed at the mating interface for direct mating to a mating component. The front pad 272 supports the front portion 212 of the conductor 204 in front of the mating interface 218 (e.g., in front of the wire support 280), and the rear pad 274 supports the rear portion 216 of the conductor 204 behind the mating interface 218 (e.g., behind the wire support 280). The center pad 273 supports the mating portion 214.

[0053] In an exemplary embodiment, the wire support 280 includes a channel 282 with curved sidewalls 284, 286 on opposite sides of the channel 282. The sidewalls 284, 286 hold the wire 208 within the channel 282. The wire support 280 provides a backing surface for the wire 208 (e.g., above or below the wire 208). The wire support 280 provides a rigid surface to support the wire 208. In an exemplary embodiment, the wire support 280 includes a raised platform 288 that supports the conductor 204 in an elevated position relative to the front base 265 and the rear base 267. The raised platform 288 may form a central solder pad 273. The raised platform 288 is not coplanar with the front base 265 and the rear base 267. In an exemplary embodiment, the wire support 280 includes an arch 289 forming the raised platform 288. An arch 289 is located between the front solder pad 272 and the rear solder pad 274. The arch 289 supports the wire 208. The arch 289 has an arcuate shape. In alternative embodiments, other shapes are possible, such as trapezoidal, rectangular, or other shapes. In an exemplary embodiment, the arch 289 supports and positions the cable 202 at the mating interface. The arch 289 can provide a normal force that presses the cable 202 outward at the mating interface for mating with the second electrical connector 300. For example, the arch 289 provides mechanical support for the cable 202. In various embodiments, the arch 289 can be flexible and configured to be partially compressed or deflected inward when the terminal assembly 250 mates with the terminal assembly of the second electrical connector 300 to generate an internal biasing force configured to bias the cable 202 outward at the mating interface for direct interfacing with the cable 302 of the second electrical connector 300. In various embodiments, the raised platform 288 may include a flat portion to hold the wire 208 and define a flat mating interface. For example, conductor 204 may include a flat mating interface for mating with mating parts. The flat portion may form a central solder pad 273.

[0054] In an exemplary embodiment, terminal 260 includes a retaining latch 290 for holding terminal 260 within housing 220. The retaining latch 290 extends from body 262. In the illustrated embodiment, the retaining latch 290 is located near rear portion 266. Other locations are possible in alternative embodiments.

[0055] In an exemplary embodiment, terminal 260 includes sidewalls 292 extending from opposite sides of body 262. Sidewalls 292 can be used to gather and position wires 208 relative to body 262. In the illustrated embodiment, sidewalls 292 are parallel to each other. In alternative embodiments, other orientations are possible. Sidewalls 292 can be used to position terminal 260 within housing 220. In an exemplary embodiment, sidewalls 292 include alignment features 294 for aligning terminal 260 within housing 220. In the illustrated embodiment, sidewalls 292 are located near rear portion 266. In alternative embodiments, other locations are also possible.

[0056] In an exemplary embodiment, terminal 260 includes a front alignment feature 296 at a front portion 264 of terminal 260. The front alignment feature 296 is used to align terminal 260 within housing 220. In the illustrated embodiment, the front alignment feature 296 includes alignment tabs extending from the side of a front base 265. The alignment tabs may be coplanar with the front base 265. Other types of alignment features may be used in alternative embodiments.

[0057] Figure 10 A plurality of terminals 260 on a carrier strip according to an exemplary embodiment are shown. Figure 11 This is a front perspective view of the terminal assembly 250 according to an exemplary embodiment, showing the terminal 260 connected to the end of the cable 202. Figure 11 Terminals 260 of conductor 204 soldered to cable 202 are shown. In an exemplary embodiment, conductor 204 is a multi-strand conductor having a plurality of wires 208 forming conductor 204. The wires 208 are arranged in bundles, for example, in multiple layers. Exposed portions 210 of conductor 204 are received in terminals 260 and positioned to mate with conductor 304 of second electrical connector 300.

[0058] Terminal 260 is stamped from a single sheet of metal and formed into a predetermined shape to receive the end of cable 202. Terminal 260 includes a body 262 extending between a front portion 264 and a rear portion 266. Body 262 includes a front base 265 and a rear base 267. Wire support 280 is located between the front base 265 and the rear base 267. Terminal 260 provides mechanical support for cable 202, for example, positioning the conductor 204 of cable 202 for direct engagement with mating parts. Front solder pad 272 is disposed at the front base 265 and soldered to the front portion 212 of conductor 204. For example, individual wires 208 can be soldered together and soldered to terminal 260 at front solder pad 272. Rear solder pad 274 is disposed at the rear base 267 and soldered to the rear portion 216 of conductor 204. For example, individual wires 208 can be soldered together and soldered to terminal 260 at rear solder pad 274. The insulating crimping part 276 is crimped to the insulator 206.

[0059] The wire support 280 supports the conductor 204 at the mating interface 218 for direct mating with the second electrical connector 300 (e.g., a mating interface of a conductor mating to a corresponding terminal assembly of the second electrical connector 300 or a contact pad mating to a circuit board). In an exemplary embodiment, a central solder pad 273 is disposed along the wire support 280 for soldering to the mating portion 214 of the conductor 204. For example, individual wires 208 may be soldered together and soldered to the terminal 260 at the central solder pad 273. In an alternative embodiment, the mating portion 214 of the conductor 204 may be freely supported (not soldered) between the front solder pad 272 and the rear solder pad 274. The outer surface 219 of the conductor 204 (e.g., the outer surface of the outermost wire 208) is exposed at the mating interface for direct mating to the mating component. An arch 289 of the wire support 280 is located between the front solder pad 272 and the rear solder pad 274. The arch 289 provides a rigid surface to support the wire 208, for example in the channel 282 at the raised platform 288.

[0060] Figure 12 This is a cross-sectional view of a first electrical connector 200 according to an exemplary embodiment. The electrical connector 200 includes a housing 220 that holds a terminal assembly 250 in a terminal channel 240. The housing 220 extends between a mating end 222 and a cable end 224 from which a cable 202 extends. The housing 220 includes a mating groove 242 at the mating end 222 (e.g., the front portion) between an upper wall 241 and a lower wall 243. The terminal assembly 250 is exposed in the mating groove 242 for mating with a mating member. The lower wall 243 may receive the terminal assembly 250.

[0061] Figure 13 An electrical connector system 100 is shown, illustrating first and second electrical connectors 200 and 300 in a mating state. When mated, an upper wall 241 is configured to insert into a mating groove of the second electrical connector 300. The mating groove 242 is configured to receive a portion of the second electrical connector 300. A terminal assembly 250 is configured to mate with a terminal assembly 350 of the second electrical connector 300. A latch securely holds the first electrical connector 200 and the second electrical connector 300 in place.

[0062] Figure 14 This is a cross-sectional view of the electrical connector system 100, showing the first and second electrical connectors 200 and 300 in a mating state. Figure 15 This is an enlarged cross-sectional view of the electrical connector system 100, showing the first electrical connector 200 and the second electrical connector 300 in a mating state.

[0063] During assembly, terminal assembly 250 is loaded into terminal channel 240 of housing 220. Mating interface 218 of conductor 204 is located in mating groove 242 for mating with conductor 304 of second electrical connector 300. Terminal 260 provides mechanical support for conductor 204. For example, front pad 272 and rear pad 274 secure conductor 204 at front portion 212 and rear portion 216, respectively. Central pad 273 secures mating portion 214 of conductor 204. Wire support 280 (e.g., arch 289) supports and positions cable 202 at mating interface. Terminal 260 can provide an outward pressing force against cable 202 to press cable 202 outward at mating interface for mating with cable 302 of second electrical connector 300. For example, terminal 260 provides mechanical support for cable 202. In various embodiments, terminal 260 may be flexible and configured to be partially compressed or inwardly deflected when terminal assembly 250 mates with terminal assembly 350 of second electrical connector 300 to generate an internal biasing force configured to bias cable 202 outward at the mating interface for direct connection to cable 302 of second electrical connector 300.

[0064] Terminal 260 can be a low-cost terminal, for example, made of a low-cost material, such as stainless steel instead of copper, because terminal 260 does not need to form an electrical connection or interface, but is used for mechanical support. The mating portion 214 defines an electrical mating interface 218 and is configured to be directly electrically connected to the mating portion of the conductor 304 of the second electrical connector 300. The mating interface 218 at the mating portion 214 of the conductor 204 is a separable mating interface. The mating interface 218 at the mating portion 214 of the conductor 204 can be a wipe mating interface, configured to wipe along the mating portion of the conductor 304 during mating.

[0065] Figure 16 An electrical connector system 100 is shown, which shows a first electrical connector 200 ready to mate with mating parts. Figure 17 An electrical connector system 100 is shown, illustrating a first electrical connector 200 that mates with a mating component. In the illustrated embodiment, the mating component includes a circuit board 500 having contact pads 502 at an edge 504 of the circuit board 500. A connector housing 520 is mounted to the circuit board 500 and has a cavity 522 for receiving the first electrical connector 200. For example, the housing 220 of the first electrical connector 200 is inserted into the cavity 522 to mate a terminal assembly 250 with the contact pad 502. The edge 504 of the circuit board 500 can be inserted into a mating groove 242. In various embodiments, one of the walls (e.g., the lower wall) can be removed, such that the mating groove 242 opens at the bottom.

[0066] Figure 18This is a cross-sectional view of an electrical connector system 100, showing a first electrical connector 200 that mates with mating parts. Figure 19 This is an enlarged cross-sectional view of the electrical connector system 100, showing the first electrical connector 200 that mates with mating parts.

[0067] During assembly, terminal assembly 250 is loaded into terminal channel 240 of housing 220. Mating interface 218 of conductor 204 is located in mating groove 242 for mating with contact pad 502 of circuit board 500. Terminal 260 provides mechanical support for conductor 204. For example, front pad 272 and rear pad 274 secure conductor 204 at front portion 212 and rear portion 216, respectively. Central pad 273 secures mating portion 214 of conductor 204. Wire support 280 (e.g., arch 289) supports and positions cable 202 at mating interface. Terminal 260 can provide an outward pressing force against cable 202 to press cable 202 outward at mating interface for mating with cable 302 of second electrical connector 300. For example, terminal 260 provides mechanical support for cable 202. In various embodiments, terminal 260 may be flexible and configured to be partially compressed or inwardly deflected when terminal assembly 250 mates with terminal assembly 350 of second electrical connector 300 to generate an internal biasing force configured to bias cable 202 outward at the mating interface for direct interface with cable 302 of second electrical connector 300.

[0068] Terminal 260 can be a low-cost terminal, for example, made of a low-cost material, such as stainless steel instead of copper, because terminal 260 does not need to form an electrical connection or interface, but is used for mechanical support. The mating portion 214 defines an electrical mating interface 218 and is configured to be directly electrically connected to the contact pad 502 of the circuit board 500. The mating interface 218 at the mating portion 214 of the conductor 204 is a separable mating interface. The mating interface 218 at the mating portion 214 of the conductor 204 can be a wipe mating interface, configured to wipe along the contact pad 502 of the circuit board 500 during mating.

[0069] Figure 20 An electrical connector system 100 is shown, illustrating a first electrical connector 200 that mates with a mating component. In the illustrated embodiment, the mating component includes an electrical connector 600 coupled to a circuit board 602. The electrical connector 600 includes a contact 604 terminating on the circuit board 602. The electrical connector 600 may be a receptacle connector. The first electrical connector 200 is configured to insert into the housing of the electrical connector 600 to mate with the contact 604.

[0070] It should be understood that the above description is intended to be illustrative and not restrictive. For example, the above embodiments (and / or aspects thereof) can be used in combination with each other. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the invention without departing from the scope of the invention. The dimensions, material types, orientations of various components, and the number and position of various components described herein are intended to define parameters of certain embodiments and are by no means restrictive, but merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those skilled in the art upon reading the above description. Therefore, the scope of the invention should be determined by reference to the appended claims and the full scope of their equivalents. In the appended claims, the terms “comprising” and “therein” are used as concise English equivalents of the corresponding terms “including” and “wherein”. Furthermore, in the following claims, the terms “first,” “second,” and “third,” etc., are used only as designations and are not intended to impose numerical requirements on their objects. Furthermore, the limitations of the following claims are not written in the form of means plus function, and are not intended to be interpreted based on 35 U.SC §112(f), unless and until such a claim limitation expressly uses the phrase “means for…” followed by a functional statement without further structure.

Claims

1. A terminal assembly, comprising: A cable, the cable comprising a conductor having at least one filament, the conductor having an outer surface; and A terminal having a body extending between a front portion and a rear portion of the terminal, the terminal including a wire support member that supports at least one wire of the conductor at a mating interface, the at least one wire being soldered to the wire support member to secure the at least one wire to the body of the terminal; The outer surface of the conductor is exposed at the mating interface for direct mating with the mating component.

2. The terminal assembly according to claim 1, wherein, The at least one wire is exposed at the mating interface for directly mating the conductor to the mating component.

3. The terminal assembly according to claim 1, wherein, The wire support includes a solder pad, to which at least one wire is soldered.

4. The terminal assembly according to claim 1, wherein, The wire support includes a front solder pad and a rear solder pad, and at least one wire is soldered to the front solder pad and the rear solder pad, with the mating interface located between the front solder pad and the rear solder pad.

5. The terminal assembly according to claim 1, wherein, At least one wire is welded to the wire support at the mating interface.

6. The terminal assembly according to claim 1, wherein, The main body includes a front wire crimping part and a rear wire crimping part, and the wire support is located between the front wire crimping part and the rear wire crimping part. The front wire crimping part and the rear wire crimping part are crimped to the at least one wire in front of and behind the mating interface.

7. The terminal assembly according to claim 1, wherein, The thread support includes a channel having curved sidewalls that hold at least one thread.

8. The terminal assembly according to claim 1, wherein, The wire support includes a front base supporting the conductor at the front of the terminal and a rear base supporting the conductor at the rear of the terminal, the mating interface being located between the front base and the rear base, and the at least one wire being welded to the body at the front base and the rear base.

9. The terminal assembly according to claim 8, wherein, The wire support includes a lifting platform that supports the conductor at an elevated position relative to the front base and the rear base.

10. The terminal assembly according to claim 1, wherein, The thread support includes an arch that supports at least one thread, the arch having an arc shape.

11. The terminal assembly according to claim 1, wherein, The at least one wire is ultrasonically welded to the body of the terminal.

12. The terminal assembly according to claim 1, wherein, The at least one wire includes a first wire and a second wire, wherein the first wire is welded to the second wire.

13. The terminal assembly according to claim 1, wherein, The at least one thread comprises multiple threads interlaced at the mating interface.

14. The terminal assembly according to claim 1, wherein, The terminal is made of stainless steel.

15. The terminal assembly of claim 14, wherein, The terminal assembly has a density greater than 3.0 × 10⁻⁶ at 20°C. 7 Conductivity in S / m.

16. The terminal assembly according to claim 1, wherein, The terminal has a conductivity of less than 30 IACS.

17. The terminal assembly according to claim 1, wherein, The body of the terminal is outside the mating interface, and the body is configured not to be in contact with the mating component.

18. A terminal assembly, comprising: A cable, the cable comprising a conductor having at least one filament, the conductor comprising a front portion, a rear portion, and a mating portion between the front portion and the rear portion; and A terminal having a body extending between a front portion and a rear portion thereof, the terminal including a front solder pad soldered to a front portion of the conductor, the terminal including a rear solder pad soldered to a rear portion of the conductor, and the terminal including a wire support supporting a mating portion of the conductor at a mating interface; The mating portion of the conductor is exposed at the mating interface for direct mating to the mating component.

19. An electrical connector, comprising: A housing having a mating end and a cable end, the mating end being configured to mate with a mating component, the housing including a contact channel passing through the housing; and A terminal assembly coupled to the housing, the terminal assembly including a cable and a terminal coupled to the cable, the cable including a conductor having at least one wire, the terminal having a body extending between a front portion and a rear portion of the terminal, the terminal including a wire support supporting the at least one wire of the conductor at a mating interface, the at least one wire being soldered to the wire support to secure the at least one wire to the body of the terminal, wherein the conductor is exposed at the mating interface for direct mating to the mating member.

20. The electrical connector according to claim 19, wherein, The housing includes a mating groove configured to receive the mating component, the mating interface being exposed within the mating groove to mate with the mating component.

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